Lincoln Electric RANGER 9 IM753-A Operator's Manual

RANGER 9

This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Specications and availability of optional
features may have changed.

Multi-Process Gasoline Engine Driven Welder and Power Generator

For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought­ful operation on your part. DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most

importantly, think before you act
and be careful.

10909, 10939

™

IM753-A

January, 2003

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

OPERATOR’S MANUAL

Copyright © 2003 Lincoln Global Inc.

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

• Sales and Service through Subsidiaries and Distributors Worldwide •

• World's Leader in Welding and Cutting Products •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

vapors

Mar ‘95

to

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

vv

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications ................................................................................................A-1,A-2

Installation Instructions.........................................................................................................A-3

Undercarraiges..............................................................................................................A-3

Safety Precautions ........................................................................................................A-3

Spark Arrester ...............................................................................................................A-3

Machine Grounding.......................................................................................................A-3

Welding Output Cables .................................................................................................A-4

Additional Safety Precautions .......................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-4

Oil..................................................................................................................................A-4

Fuel ...............................................................................................................................A-4

Engine Coolant..............................................................................................................A-4

Battery Connections......................................................................................................A-4

Exhaust Deflector..........................................................................................................A-4

High Altitude Operation .................................................................................................A-5

Electrical Connections..........................................................................................................A-6

Remote Outpit Control ..................................................................................................A-6

Welding Cable Connections..........................................................................................A-6

Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment ........................................A-7

Standby Power Connections ................................................................................................A-8

Premises Wiring ...................................................................................................................A-9

vi

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Recommended Applications.................................................................................................B-2

Auxiliary Power.....................................................................................................................B-2

Welder Operation ................................................................................................................B-2

Fuel Consumption .........................................................................................................B-3

Welder Controls Functions and Operations ........................................................................B-3

Idler Switch ...................................................................................................................B-4

Welding ........................................................................................................................B-4

Auxiliary Power .............................................................................................................B-4

Starting / Shutdown Instructions...........................................................................................B-4

Onan Engine .................................................................................................................B-4

Kohler Engine................................................................................................................B-4

Stoping the Engine........................................................................................................B-4

Break-In Period .............................................................................................................B-4

Welding Processes...............................................................................................................B-5

AC / DC Stick (Constant Current) Welding ...................................................................B-5

AC / DC TIG (Constant Current) Welding .....................................................................B-5

Wire Feed (Constant Voltage) Welding.........................................................................B-5

Summary of Welding Processes ..................................................................................B-6

________________________________________________________________________________

Accessories.....................................................................................................Section C

General Options / Accessories..............................................................................C-1

TIG Welding Options / Accessories.......................................................................C-1

vii

TABLE OF CONTENTS

Page

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Engine Adjustments...............................................................................................D-1

Overspeed Is Hazardous.......................................................................................D-1

Routine Maintenance.............................................................................................D-1

Oil....................................................................................................................D-1

Engine Oil Change .........................................................................................D-1

Engine Oil Refill Capacities.............................................................................D-2

Oil Filter Change .............................................................................................D-2

Slip Rings........................................................................................................D-2

Air Cleaner ......................................................................................................D-2

Battery Charging .............................................................................................D-3

Battery.............................................................................................................D-3

Hardware ........................................................................................................D-3

Engine Maintenance Parts..............................................................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

Safety Precautions.................................................................................................E-1

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-5

________________________________________________________________________

Wiring Diagrams, Dimension Print ................................................................Section F

________________________________________________________________________

Parts List..................................................................................................................P230

________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 9 (K1420-3,K1421-3)

INPUT - GASOLINE ENGINE

A-1

Make/Model Description Horsepower Operating Displacement

@ 3600 RPM SPEED Bore x Stroke in.(mm) System

Ranger 9 2 Cylinder

Onan P220 4 Cycle 3700RPM ( 653 cc in ) Cold Cranking Lubricating Oil :

{OHV} Air cooled Amps, Toggle 1.6 Qts. (1.5L)

Gasoline Start Switch,

Engine

Aluminum Alloy 3500RPM Manual Choke

Block with Cast

Ranger 9 Iron Liners & Fuel: 9 gal (34L)

Kohler Electronic

Command Ignition 2200RPM ( 624 cc in) 2.0 Qts. (1.9L)

CH20S

20.5 HP High Idle 39.9 cu in 12V Battery Fuel:

Full Load Charging Ammeter

20 HP Low Idle 38.1 cu in

cu. in.(cu. cm)

Starting Capacities

9 gal.

(34L)

Lubricating Oil :

RATED DC OUTPUT - WELDER

Welding Output Volts at Rated Amps * Duty Cycle Max. OCV @ 3700 RPM

AC Constant Current 25 Volts at 250 Amps

DC Constant Current 25 Volts at 250 Amps 100% 80 Volts

DC Constant Voltage 25 Volts at 250 Amps

MACHINE OUTPUT - GENERATOR

Description Auxiliary Power for wire feeders AC Power * *

250 Amp AC/DC Multi-Process 42V, 60 Hz, 8 Amps 9,000 Watts 60 Hz. DC

Arc Welder with 40 Amps @ 115V

9,000 Watts AC Auxiliary Power 115V, 60 Hz, 8 Amps 40 Amps @ 230V

40 Amps @ Duplex Outlet

PHYSICAL DIMENSIONS

MODEL HEIGHT WIDTH DEPTH WEIGHT

Ranger 9 Onan 30.3 in ( 770 mm ) 19.2 in ( 488 mm ) 42.3 in ( 1075 mm ) 598 lbs ( 272 kg

{P220 OHV}

Ranger 9 ( Kohler 591 lbs ( 269 kg )

Command CH20S )

* Based on a 10 min. period.
* * When welding, available AC auxiliary power will be reduced.

115V will operate either 60 Hz or 50/60 Hz power tools, lights, etc.

RANGER 9

A-2

SPECIFICATIONS

80

70

60

50

40

30

INSTALLATION

AC STICK / TIG (CC) OUTPUT

250

A 225 OUTPUT RANGE

45

B 50 OUTPUT RANGE

A-2

20

OUTPUT VOLTS AC (RMS)

10

0

80

70

60

50

40

30

20

OUTPUT VOLTS DC (RMS)

10

0

B

A

0

0 50 100 150 200 250 300 350

0 50 100 150 200 250 300 350 400 450

0

50 100 150 200

OUTPUT AMPS

DC STICK / TIG (CC) OUTPUT

250

A 210 OUTPUT RANGE

45

B 50 OUTPUT RANGE

B

50 100 150

A

200 250 300

OUTPUT AMPS

250

350

55
50
45
40
35
30
25
20
15

OUTPUT VOLTS DC

10
5
0

HIGH

MED

LOW

0 50 100 150 200 250 300 350 400

OUTPUT AMPS

RANGER 9

A-3

INSTALLATION

INSTALLATION INSTRUCTIONS

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

--------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

--------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

--------------------------------------------------------

See additional warning information at

front of this operator’s manual.

A-3

Where this engine driven welder is connected to
premises wiring such as that in your home or shop,
it’s frame must be connected to the system earth
ground. See further connection instructions in the
section entitled “Standby Power Connections”, as well
as the article on grounding in the latest U.S. National
Electrical Code and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a
solid earth ground such as a metal water pipe going
into the ground for at least ten feet and having no
insulated joints, or to the metal framework of a build­ing which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate
means of grounding electrical equipment. A machine
grounding stud marked with the symbol is provid­ed on the front of the welder.

SPARK ARRESTER

Some federal, state, or local laws may require that
gasoline engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard.
The standard muffler included with this welder does
not qualify as a spark arrester. When required by
local regulations, the K894-1 spark arrester must be
installed and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

------------------------------------------------------------------------

MACHINE GROUNDING

Because this portable engine driven welder or genera­tor creates it’s own power, it is not necessary to con­nect it’s frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).

To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:

• Be grounded to the frame of the welder using a

grounded type plug, or

• Be double insulated.

When this welder is mounted on a truck or trailer, it’s
frame must be securely connected to the metal frame
of the vehicle.

RANGER 9

UNDERCARRIAGES

The recommended trailer for use with this equipment
for in plant and yard towing by a vehicle (1) is
Lincoln’s K768-2. If the user adapts a non-Lincoln
undercarriage, he must assume responsibility that the
method of attachment and usage does not result in a
safety hazard nor damage the welding equipment.

Some of the factors to be considered are as follows:

• Design capacity of undercarriage vs. weight of
Lincoln equipment and likely additional attach­ments

• Proper support of, and attached to, the base of the
welding equipment so there will be no undue stress
to the frame work.

• Proper placement of the equipment on the under­carriage to ensure stability side to side and front to
back when being moved and when standing by
itself while being operated or serviced.

A-4

• Typical conditions of use, i.e., travel speed; rough­ness of surface on which the trailer will be operated;
environmental conditions; like maintenance.

• Conformance with federal, state and local laws.(1)

(1)

Consult applicable federal, state and local laws
regarding specific requirements for use on public
highways.

INSTALLATION

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance
instructions supplied with this machine.

WARNING

GASOLINE

• Wipe up spilled fuel and allow fumes to clear
before starting engine.

fuel can cause fire or explosion.

• Stop engine while fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Keep sparks and flame away from
fuel tank.

-

A-4

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces­sary. Loose connections will result in overheating of
the output studs.

When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

250 Amps

40% Duty Cycle

0-50 Ft.(15.2M)

50-100 Ft.(15.2-30.5M)

2 AWG

2 AWG

250 Amps

100% Duty Cycle

1 AWG

1 AWG

Oil

The Ranger 9 is shipped with the engine crankcase
filled with SAE 10W-30 oil. Check the oil level before
starting the engine. If it is not up to the full mark on the
dip stick, add oil as required. Make certain that the oil
filler cap is tightened securely. Refer to the engine
Owner’s Manual for specific oil recommendations.

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Onan P220 - 1.65 Quarts (1.6 Liters)

Kohler CH20S - 2.0 Quarts (1.9 Liters)

Fuel

Fill the fuel tank with clean, fresh, lead-free gasoline.
The capacity is approximately 9 gallons (34 liters).
Observe fuel gauge while filling to prevent overfilling.

BATTERY CONNECTIONS

This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
discharged and does not have enough power to start
the engine, see the battery charging instructions in the
Battery section.

100-150 Ft.(30.5-45.7M)

150-200 Ft.(45.7-61.0M)

200-250 Ft.(61.0-76.0M)

2 AWG

1 AWG

1/0 AWG

1 AWG

1 AWG

1/0 AWG

LOCATION/VENTILATION

The welder should be located to provide an unrestrict­ed flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the back of the welder
recirculating back to the cooling air inlets below the
exhaust. Also, locate the welder so that the engine
exhaust fumes are properly vented to an outside area.

WARNING

Damage to fuel tank may cause fire or explosion.
Do Not
the Ranger 9 base.

------------------------------------------------------------------------

drill holes in the Ranger 9 base or weld to

RANGER 9

A-5

INSTALLATION

A-5

ANGLE OF OPERATION

Internal combustion engines are designed to run in a
level condition which is where the optimum perfor­mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintain­ing the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.

When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 10
gallons.

HIGH ALTITUDE OPERATION

If the Ranger 9 will be consistently operated at alti­tudes above 5000ft.(1524m), a carburetor jet
designed for high altitudes should be installed. This
will result in better fuel economy, cleaner exhaust,
and longer spark plug life. It will not
power which is decreased at higher altitudes. Engine
horsepower is reduced by 3.5% per 1000ft.(304.8m)
for altitudes above 377ft.(114.9m).

give increased

CAUTION

Do not operate a Ranger 9 with a high altitude jet
installed at altitudes below 5000ft.(1529m). This
will result in the engine running too lean and
result in higher engine operating temperatures
which can shorten engine life.

-----------------------------------------------------------------------

High altitude jet kits are available from the engine
manufacturer. Contact your local Onan, or Kohler
Authorized Dealer.

Muffler Relocation

WARNING

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off welder before making any electrical
connections.

-----------------------------------------------------------------------

Connection of the LN-7 or LN-8 to the
Ranger 9.

•

Shut off the welder.

• Connect the LN-7 or LN-8 per the instructions on
the the appropriate connection diagram in the rear
of this manual.

• Set the output control toggle switch to appropriate
position: “CONTROL REMOTE” for LN-8 and LN-7
with K857 attached; “CONTROL AT WELDER’ for
LN-7 with no remote voltage control.

• Set “POLARITY” switch to either WIRE FEED DC+
or WIRE FEED DC-.

* Set the “RANGE” switch to either HIGH, MED or

LOW as required by the process.

• Set the ‘WELDING TERMINALS” Control switch to
the ‘REMOTELY CONTROLLED” position.

• Set the ‘IDLER” switch to the “HIGH”idle position.

Connection of the LN-742 to the Ranger 9.

• Shut off the welder.

• Connect per the instructions on the appropriate con
nection diagram in the rear of this manual.

Shut off welder and allow muffler to cool before
touching muffler.

The Ranger 9 is shipped with the exhaust coming
out on the left side. The exhaust can be changed
to the opposite side by removing the two screws
that hold the exhaust port cover in place and
installing the cover on the opposite side.

(Operating the Ranger 9 without the cover in
place will result in a higher noise level and no
increase in machine output.)

---------------------------------------------------

• Set the output control toggle switch to ‘CONTROL
AT WELDER” when not using remote control.
When the LN-742 has a K589-1 remote control
attached, set output control to “REMOTE”.

• Set “POLARITY” switch to either WIRE FEED DC+
or WIRE FEED DC-.

• Set the ‘RANGE’”switch to either HIGH, MED or
LOW as required by the process.

• Set the ‘WELDING TERMINALS” Control switch to
the ‘REMOTELY CONTROLLED” position.

• Set the ‘IDLER” switch to the “AUTO” idle position.

RANGER 9

A-6

INSTALLATION

A-6

Connection of K428 or K446 LN-25 with
K624-1 42 volt Remote Output Control
Module to the Ranger 9

Requires K626-xx Control Cable. Provides “ cold “ elec­trode until gun trigger is pressed and also provides volt­age control at the feeder. The K446 LN-25 includes a
gas solenoid. See the appropriate connection diagram
in rear of this manual.

• Shut the welder off.

•

Connect the electrode cable from the LN-25 to the

“ELECTRODE” stud of the welder. Connect the

work cable to the “TO WORK” stud of the welder.

• Connect the control cable from the LN-25 to the
14 pin amphenol on the Ranger 9.

• Attach the single lead from the front of the LN-25 to
the work using the spring clip on the end of the lead

This is a control lead to supply the current to the

wire feeder motor; it does not carry welding current.

• Set the “POLARITY” switch to either WIRE FEED
DC+ or WIRE FEED DC- as required by the elec­trode being used.

• Set the “WELDING TERMINAL” Control switch to
the “ALWAYS ON” position.

• Set the “IDLER” switch to the “AUTO” position.

Connection of the Magnum Spool Gun
and SG Control Module to the Ranger 9

• Shut off the welder.

• Connect per the instructions on the appropriate con­nection diagram in the rear of this manual.

• Set the output control toggle switch to ‘CONTROL
AT WELDER” when not using remote control.

• Set “POLARITY” switch to either WIRE FEED DC+.

* Set the ‘RANGE” switch to either HIGH, MED or

LOW as required by the process.

• Set the ‘WELDING TERMINALS” Control switch to
the ‘REMOTELY CONTROLLED” position.

• Set the ‘IDLER” switch to the ‘HIGH” idle position.

Connection of Spool Gun to LN-25 with
contactor, soleniod K449 .

• Set the “RANGE” switch to either HIGH,MED or
LOW as required by the process.

• Set the “WELDING TERMINALS” Control switch to

the “REMOTELY CONTROLLED” position.

• Place the idler switch in the “AUTO” position.

Connection of the K449 LN-25 to the
Ranger 9.

• Shut off the welder.

• Connect the electrode cable from the LN-25 to the

“ELECTRODE” stud of the welder. Connect the work

cable to the “TO WORK” stud of the welder.

• Attach the single lead from the front of the LN-25 to

work using the spring clip on the end of the lead.
This is a control lead to supply the current to the
wire feed motor; it does not carry welding current.

• Set the “POLARITY” switch to either WIRE FEED

DC+ or WIRE FEED DC - as required by the
electrode being used.

• Set the “RANGE” switch to either HIGH, MED or

LOW as required by the process.

High Frequency Generator for TIG weld­ing applications

The K930-1 TIG Module is an accessory that provides
high frequency and shielding gas control for AC and
DC GTAW (TIG) welding. See IM528 supplied with
the TIG Module for installations instructions.

Note: The TIG Module does not require the use of a
high frequency bypass capacitor. If any other high fre­quency accessary is used with the Ranger 9, a
bypass capacitor (Order Kit T12246) must be installed
in the Ranger 9.

REMOTE OUTPUT CONTROL

The Ranger 9 has a 6-pin and a 14-pin connector.
These connectors are located above the output studs.
The 6-pin connector is intended to be used with the
optional K857 Remote Output Control or in the case of
TIG welding applications, with the Foot or Hand
Amptrol. The 14-pin connector is used to connect a
wire feeder control cable. If the wire feeder has a built­in power source output control, do not connect a
remote output control to the 6-pin connector. When
remote output control is used, the output control tog­gle switch is to be set at “CONTROL REMOTE”.

RANGER 9

A-7

INSTALLATION

AUXILIARY POWER

The Ranger 9 can provide up to 9,000 watts of
115/230 volts AC, single phase 60Hz power for contin­uous use. The front of the machine includes three
receptacles for connecting the AC power plugs ; one
50 amp 115/230 volt NEMA 14-50R receptacle and
two 20 amp 115 volt NEMA 5-20R receptacles.
Do not connect any plugs that connect to the power
receptacles in parallel.

Start the engine and set the “IDLER” control switch to
the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptacles for auxil­iary power.

115/230 VOLT DUAL VOLTAGE RECEPTACLE

The 115/230 volt receptacle can supply up to 40 amps
of 230 volt power to a two wire circuit, up to 40 amps
of 115 volt power from each side of a three wire circuit
(up to 80 amps total). Do not
cuits in parallel. Current sensing for the automatic idle
feature is only in one leg of the three wire circuit as
shown.

connect the 115 volt cir-

GND

A-7

115V DUPLEX RECEPTACLE

The 115V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs.

The current rating of any plug used with the system
must be at least equal to the current load through the
associated receptacle ( Refer to Tables l and ll ). Do
not attempt to connect power receptacles in parallel.

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a

1.5 hp motor is approximately 20 amperes (10
amperes for 230 volt motors). The motor may be run
at full load when plugged into only one side of the
duplex receptacle. Larger motors through 2 hp can be
run provided the receptacle rating as previously stat­ed is not exceeded. This may necessitate 230V oper­ation only.

AUXILIARY POWER WHILE WELDING

It must be noted that the above auxiliary power ratings
are with no welding load. Simultaneous welding and
power loads are permitted by following the Table. The
permissible currents shown assume that current is
being drawn from either the 115V or 230V supply (not
both at the same time).

115 V

115 V*

*Current Sensing for Automatic Idle.
(Receptacle viewed from front of Machine)

230 V

NOTE: Voltage and permissible watts decrease as

“CONTROL” is adjusted to settings less than 10. IT is
recommended that at settings less than 10, only
incandescent lighting loads be connected to the auxil­iary power receptacles.

RANGER 9

A-8

INSTALLATION

STANDBY POWER CONNECTIONS

The Ranger 9 is suitable for temporary, standby, or
emergency power using the engine manufacturer’s rec­ommended maintenance schedule.

The Ranger 9 can be permanently installed as a stand­by power unit for 230V-3 wire, single phase 40 ampere
service.

WARNING

(Connections must be made by a licensed electri­cian who can determine how the 115/230V power
can be adapted to the particular installation and
comply with all applicable electrical codes.) The
following information can be used as a guide by the
electrician for most applications (refer also to the
connection diagram shown )

IMPORTANT : When the Ranger 9 is connected to a

230 volt, 3-wire line, the unit should be operated with
the idler switch in the “HIGH” idle position to avoid load
sensing problems. If the machine is set for automatic
idle, the 230 volt circuit will sense loads and cause the
engine to accelerate to high idle. However, since only
one line of the circuit senses current, 115 volt power
drawn from only one line to neutral may result in the
engine not going to high idle.

A-8

• Install a double pole, double throw switch between

the power company meter and the premises
disconnect.
Switch rating must be the same or greater than
the customer’s premises disconnect and service
overcurrent protection.

• Take necessary steps to assure load is limited to
the capacity of the Ranger 9 by installing a 40 amp
230V double pole circuit breaker. Maximum
rated load for the 230V auxiliary is 40 amperes.
Loading above 40 amperes will reduce output
voltage below the allowable -10% of rated
voltage which may damage appliances or other
motor-driven equipment.

• Install a 50 amp 115/230V plug (NEMA type 14-50)

to the Double Pole Circuit Breaker using No. 8, 4
conductor cable of the desired length. See
Accessories Section for (The 50 amp 115/230V
plug kit.)

• Plug this cable into the 50 amp 115/230 V
receptacle on the Ranger 9 case front.

SIMULTANEOUS WELDING AND POWER

Output Welding Permissible Permissible Permissible

Selector Setting Output Power Watts Auxiliary Current in Auxiliary Current in

(Unity Power Factor) Amperes @ 115V * Amperes @ 230V

250 250 NONE
200 200 2500 22 11
160 160 3700 32 16
120 120 5000 44 * * 22

90 90 6000 52 * * 26
45 45 7500 65 * * 32.5

CV LOW 250 5000 43 * * 21.5

60 7500 65 * * 32.5

CV MEDIUM 250 2750 40 * * 20

80 6500 56 * * 28

CV HIGH 250 1200 10 5

100 6000 52 * * 26

* Each duplex receptacle is limited to 20 amps.

* * Not to exceed 35A per 115 VAC branch circuit when splitting the 230 VAC output.

RANGER 9

A-9

230 Volt

60 Hz.
3-Wire

Service

CONNECTION OF RANGER 9 TO PREMISES WIRING

230 VOLT

POWER

COMPANY

METER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

INSTALLATION

115 VOLT

115 VOLT

35AMP

230 VOLT

GROUNDED CONDUCTOR

NEUTRAL
BUS

GROUND

A-9

N

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

LOAD

DOUBLE

50 AMP, 115/230

VOLT PLUG

NEMA TYPE 14-50

230 VOLT

50 AMP, 115/230 VOLT

RECEPTACLE

POLE

CIRCUIT

BREAKER

GND

N

NOTE: No. 8 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

WARNING

• Only a licensed, certified, trained electrician should install the machine to a premises or residential
electrical system. Be certain that:

•The installation complies with the National Electrical Code and all other applicable electrical codes.

•The premises is isolated and no feedback into the utility system can occur. Certain state and local
laws require the premises to be isolated before the generator is linked to the premises. Check your
state and local requirements.

•A double pole, double throw transfer switch in conjunction with the properly rated double throw
circuit breaker is connected between the generator power and the utility meter.

RANGER 9

B-1

OPERATION

B-1

SAFETY INSTRUCTIONS

Read and understand this entire section before oper­ating your RANGER 9.

WARNING

Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance instructions; and parts
lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrodes with your skin or wet cloth­ing.

• Insulate yourself from the work and
ground.

WARNING

ARC RAYS can burn.

• Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust to the outside.

• Do not stack anything on or near the
engine.

MOVING PARTS can injure.

• Do not operate this equipment with
any of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

• Always wear dry insulating gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

WELDING
SPARKS can cause fire or explo­sion.

• Keep flammable material away.

• Do not weld on containers that have

held combustibles.

Only qualified personnel should install, use, or ser­vice this equipment.

Additional Safety Precautions

Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air flow.

Read carefully the Safety Precautions page in the
Instruction Manual before operating this machine.
Always follow these and any other safety procedures
included in this manual and in the Engine Instruction
Manual.

GENERAL DESCRIPTION

The RANGER 9 TM is a twin cylinder gasoline-engine
driven, multi-process arc welder and AC power gen­erator. It is built in a heavy gauge steel case for dura­bility on the job site.

RANGER 9

B-2

OPERATION

RECOMMENDED PROCESSES AND
EQUIPMENT

The Ranger ™ 9 can be used for AC/DC Stick welding
(CC), DC Semiautomatic wire feed welding (CV),
AC/DC Tig welding (CC), and also offers a 9,000 Watt
AC 115/230 Volt, 60 Hertz power generator.

STICK:

For AC/DC Stick welding, the range is 40-250 Amps.
There is a 100% duty cycle on all settings. The Output
selector covers six ranges with remote output control
for fine current adjustment. For use with a broad range
of AC and DC electrodes including Fleetweld ® 5P.

K702 Accessory Kit which includes:

• Electrode holder and cable

• Work clamp and cable

• Headshield

K857 Remote Control Kit is optional for remote current
control.

TIG:

AC and DC TIG welding can be done at all constant
current output settings.

• Magnum ™ TIG Torch

• Magnum Parts Kit and Argon gas

• K930-1 TIG Module

• K936-1 Control Cable

B-2

LN-25 (K449) Includes internal contactor for across
the arc operation (no control cable). Provides “cold”
electrode until gun trigger is pressed. Includes gas
solenoid. K444-1 Remote Voltage Control Kit is
required for voltage control at the feeder.

LN-742 (K617-1 or K618-1) or LN-742H (K617-2 or
K618-2), requires K619-xx Input Cable Assembly.
Provides “cold” electrode until gun trigger is pressed.
Includes gas solenoid. K589-1 Remote Control Kit
connects to the LN-742 to provide remote voltage and
wire speed control or K857 Remote Voltage Control
Kit connects to the Ranger 9 for voltage control at the
feeder.

LN-7 (K521) or LN-7 GMA (K440), requires K584-xx
Input Cable Assembly. Provides “cold” electrode until
gun trigger is pressed. K440 LN-7 GMA included gas
solenoid. K857 Remote Voltage Control Kit is required
for voltage control at the feeder. Ranger 9 must be
operated at “HIGH” idle.

Magnum Gun is required for gas-shielded welding.
Innershield Gun is required for gas-less welding.

AUXILIARY POWER:

The auxiliary power is provided by a 9,000 Watt, AC
115/230 Volt, 60 Hertz generator. It will operate AC
power tools. It will also power a 1.5 HP motor (if start­ed under no load). It is capable of lighting ninety 100
Watt incandescent bulbs, and can also be used for
standby emergency power.

Optional:

* K939-1 TIG Module Docking Kit
* K963 Hand Amptrol TM
* K870 Foot Amptrol
* K814 Arc Start Switch

WIRE FEED:

For DC Semi-automatic wire feed welding, three con­stant voltage wire feed welding settings are available
giving a range of 40-250 Amps at 100% duty cycle.
Excellent performance will be obtained with a broad
range of Innershield® and Outershield® electrodes
(FCAW). Excellent arc characteristics are available
with MIG (GMAW). An output contactor is provided for
optimum semiautomatic welding.

LN-25 (428 or K446) with K624-1 42 Volt Remote
Output Control Module - Requires K626-xx Control
Cable. Provides “cold” electrode until gun trigger is
pressed. Voltage control is at the feeder. K446 LN-25
includes gas solenoid.

All Ranger 9 machines have two 20 amp circuit break­ers for 115V auxiliary receptacles and two 50 amp cir­cuit breakers for 230V receptacles. All machines are
also CSA approved.

Welder Operation RANGER 9

Constant Current 250 amps AC @ 25 volts

250 amps DC @ 25 volts

Constant Voltage 250 amps DC @ 25 volts

• Maximum Open Circuit Voltage at 3700 RPM is 80 volts

• Duty Cycle: 100% for both welding and auxiliary power.

RANGER 9

B-3

OPERATION

Ranger 9 Approximate Fuel Consumption

B-3

ONAN P220

Low Idle - No Load
2200 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
250 Amps @ 25 Volts
DC CC Weld Output
250 Amps @ 25 Volts
DC CV Weld Output
250 Amps @ 25 Volts
Auxiliary Power
9,000 KVA

.5Gallons/Hour

(1.9 Liters/Hour)

.9 Gallons/Hour

(3.4 Liters/Hour)

1.6 Gallons/Hour
(6.1 Liters/Hour)

1.9 Gallons/Hour
(7.2 Liters/Hour)

1.5 Gallons/Hour
(5.7 Liters/Hour)

1.7 Gallons/Hour
(6.4 Liters/Hour)

WELDER CONTROLS-Function and Operation

Explanation of Symbols that Appear on this Equipment

ON

OFF

Low Idle

High Idle

ENGINE “ON-OFF” SWITCH

When placed in the “ON” position, this switch
energizes the engine ignition circuit. When placed in
the “OFF” position, the ignition circuit is de-energized
to shut down the engine.

KOHLER

20 H.P. CH20S

.4 Gallons/Hour

(1.5 Liters/Hour)

1.0 Gallons/Hour
(3.8 Liters/Hour)

1.5 Gallons/Hour
(5.7 Liters/Hour)

1.7 Gallons/Hour
(6.4 Liters/Hour)

1.6 Gallons/Hour

(6.1Liters/Hour)

1.7 Gallons/Hour
(6.4 Liters/Hour)

CAUTION

Never change the “RANGE” Switch setting while
welding. This will damage the switch.

------------------------------------------------------------------------

CONTROL” SWITCH

“

Provides a fine welding current adjustment within the
Range Switch settings in the STICK/TIG mode and
welding voltage control with the Range switch set in
the wire feed mode.

ENGINE “START” PUSH BUTTON SWITCH

Energizes engine starter motor.

“POLARITY” SWITCH

Three STICK/TIG (constant current) polarity settings:

DC+,DC- and AC

Two wire feed (constant voltage) settings:

DC+ and DC-

NOTE: The setting of this switch must match the color

band setting of the Range Switch (both switches must
be set for the same welding process).

CAUTION

Never change the “POLARITY” switch setting
while welding. This will damage the switch.

“RANGE” SWITCH

Process Maximum Current

STICK/TIG - (C0instant Current) 45,90,120,

Range Settings 6 160, 200, 250

WIRE FEED - (Constant Voltage)

Range Setting 3 LOW,MED,HIGH

on Each Setting

“CONTROL AT WELDER /
REMOTE CONTROL” SWITCH

The toggle switch on he control panel labeled “CON­TROL AT WELDER” and “REMOTE CONTROL” gives
the operator the option of controlling the output at the
welder control panel or at a remote station. Remote
connections are made at the 6-pin or 14-pin amphenol
connector.

For remote control, the toggle switch is set in the
“REMOTE CONTROL” position.

For control at the welder control panel, the toggle
switch is set in the “CONTROL AT WELDER” position.

“WELDING TERMINALS” SWITCH

The Toggle switch labeled “WELDING TERMINALS
ALWAYS ON” and “WELDING TERMINALS
REMOTELY CONTROLLED” is used to control the
operation of the welder output contactor.
With the switch in the ”ALWAYS ON” position, the out­put contactor is closed at LOW and HIGH idle.

RANGER 9

B-4

With the switch in the “REMOTELY CONTROLLED”
position, the contactor is open at LOW idle and HIGH
idle until a control cable is attached to the welder
amphenol connector from a wire feeder. Under this
condition, contactor closes when the wire feeder trig­ger is depressed and opens when the trigger is
released.

IDLER” SWITCH

“

The idler switch has two positions, “HIGH” and
“AUTO”.

When in “HIGH” ( ) position, the engine will run
continuously at high idle.

When in “AUTO” (
operates as follows:

/ ) idle position, the idler

OPERATION

B-4

USE the choke control as follows:

ONAN ENGINE - If the engine is cold, pull the

choke control out. Do Not use the choke if the engine
is warm or hot.

KOHLER ENGINE - Always pull the choke control

out when starting the engine; cold, warm or hot. Place
the “Engine” switch in the “ON” position.

Push the “START” button and crank the engine until it
starts. Release the button as soon as the engine
starts. Do not push the “START” button while the
engine is running because this will cause damage to
the ring gear and / or starter motor. After the engine
has started, slowly return the choke control to the full

“in” position (choke open).

• WELDING

When the electrode touches the work, the welding arc
is initiated and the engine accelerates to full speed.
After welding ceases (and no auxiliary power is being
drawn), the engine will return to low idle after approxi­mately 10 to 14 seconds.

• AUXILIARY POWER

With the engine running at low idle and auxiliary power
for lights or tools is drawn (approximately100-150
watts or greater) from the receptacles,the engine will
accelerate to high speed. If no power is being drawn
from the receptacles (and not welding) for 10-14 sec­onds, the idler reduces the engine speed to low idle.

STARTING/SHUTDOWN Instructions

Starting the engine

WARNING

• Do not touch electrically live parts of
electrode with skin or wet clothing.

--------------------------------------------------------

• Keep flammable material away.

-------------------------------------------------------

• Insulate yourself from work and
ground. Wear eye, ear, and body pro­tection

-------------------------------------------------------

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

--------------------------------------------------------

Be sure all Pre-Operation Maintenance has been pre­formed. Also, read the Engine Owner’s Manual.
Remove all loads connected to the AC power recepta­cles. To start the engine, set the “Idler Control” switch

in the Automatic

/ position.

RANGER 9

After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.

Stop the engine by placing the “Engine” switch in the
“OFF” position.

A fuel shut off valve is not required on the Ranger 9
because the fuel tank is mounted below the engine.

BREAK-IN PERIOD

It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi­mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE SUBJECTED
TO MODERATE LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE RUNNING
PERIODS. REMOVE LOADS AND ALLOW ENGINE
TO COOL BEFORE SHUTDOWN.

The engine manufacturer’s recommendation for the
running time until the first oil change is as follows:

Kohler

CH20S

5 HRS

**

Onan

P220 OHV

20 HRS

*

* Change filter at first oil change.
** The oil filter is to be changed at the second oil

change.
Refer to the Engine Owner’s Manual for more informa­tion.

B-5

OPERATION

WELDING PROCESSES
STICK (Constant Current) Welding

Connect welding cables to the "TO WORK” and
"ELECTRODE” studs. Start the engine. Set the
"POLARITY” switch to the desired polarity. Set the
output “CONTROL” or remote output control to max
(10) and the “RANGE” switch to the setting that is
closest to the recommended current for the electrode
being used and make a trial weld. A fine adjustment of
the welding can be made by adjusting the output
“CONTROL” or remote control. For the best arc stabil­ity, always

use setting that results in the highest set­ting of the output or remote control and the lowest set­ting of the “RANGE” switch.

The Ranger 9 can be used with a broad range of AC
and DC stick electrodes. See “Welding Tips 1”
included with the Ranger 9 for electrodes within the
rating of this unit and recommended welding currents
of each. See the following table for welding current
ranges:

CURRENT RANGES ( AC and DC STICK
WELDING -5 to 10 ON CONTROL DIAL)

RANGE SETTING ACTUAL

ON MACHINE CURRENT RANGE

45 25 t0 45 AMPS
90 50 to 90 AMPS

120 60 to 120 AMPS
160 80 to 160 AMPS

B-5

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE

DIAMETER in.(mm) SETTINGS CURRENT RANGE

1/8(3.2) 90 , 120 100 - 200 Amps
3/32(2.4) 45 , 90 45 - 140 Amps
1/16(1.6) 45 , 90 45 - 100 Amps

SETTINGS FOR 1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE

DIAMETER in.(mm) SETTINGS CURRENT RANGE

1/8(3.2) 70, 90, 125, or 175 80 - 225 Amps
3/32(2.4) 50, 70, 90, or 125 50 - 180 Amps
1/16(1.6) 50, 70, or 90 45 - 120 Amps

When AC TIG welding, the actual maximum welding
current is 40 to 80 amps higher than the current
marked on the RANGE SWITCH dial. This is a result
of a lower effective reactance due to the natural rectifi­cation that occurs with the AC TIG welding process.

WIRE FEED (Constant Voltage) Welding

The Ranger 9 can be used with a broad range of flux­cored wire (Innershield and Outershield) electrodes
and solid wires for MIG welding.

When using a wire feeder with contactor control, the
electrode will be “cold” until the gun trigger is pressed.
To start the welding process, position the gun and
close the gun trigger. The contactor will close, the arc
will be initiated and the engine will accelerate to full
speed. To stop welding, release the gun trigger and
pull the gun away from the work. With the “IDLER”
SWITCH” in the “AUTO” position, the engine will go
back to low idle in approximately 12 seconds (when no
auxiliary power is drawn).

(gas metal arc welding)

200 100 to 200 AMPS
250 140 to 250 AMPS

TIG

(Constant Current) Welding

The Ranger 9 can be used in a wide variety of AC and
DC Tungsten Inert Gas (TIG) welding applications for
AC TIG welding up to 200 amps and DC TIG welding
up to 250 amps.

The K930-1 TIG Module installed on a Ranger 9 pro­vides high frequency and shielding gas control for AC
and DC GTAW (TIG) welding processes. The TIG
Module allows full range output control. After flow time
is adjustable from 0 to 55 seconds.

When using the Ranger 9 for AC TIG welding of
aluminum, the TIG Module is to be set for CONTINU­OUS HF. The following settings and electrodes are
recommended:

RANGER 9

NOTE: The LN-7 and the LN-8 must operate in the

“HIGH” idle position.

B-6

OPERATION

SUMMARY OF WELDING
PROCESSES

PROCESS CONTROL IDLE OUTPUT WELDING ELECTRODE TO START WELDING

CABLE MODE CONTROL TERMINALS STATE WHEN
USED SWITCH SWITCH NOT WELDING

Stick – CC No Auto At Welder Always on Hot Touch electrode to

work. Welding starts
immediately and engine
goes to high idle.

TIG - CC Yes Auto Remote Remote Cold Press Amptrol. Welding
K930-1/K936-1 starts immediately.
(With Amptrol)

Wire Feed - CV, Yes Auto Remote Remote Cold Press gun trigger,
LN-25 with 42V RANGER 9 contactor
Remote Control Kit closes. Welding starts

immediately and engine
goes to high idle.

B-6

Wire Feed - CV No Auto At Welder Always on Cold Press gun trigger, LN25
LN-25 with internal contactor closes. Weld­contactor ing starts immediately

and engine goes to high
idle.

Wire Feed - CV Yes Auto Remote Remote Cold Press gun trigger,
LN-742 RANGER 9 contactor

closes. Welding starts
immediately and engine
goes to high idle.

Wire Feed - CV, Yes High Remote Remote Cold Press gun trigger,
LN-7 RANGER 9 contactor

closes. Welding starts
immediately.

RANGER 9

C-1

ACCESSORIES

C-1

GENERAL OPTIONS /
ACCESSORIES

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS - For road, off-road and In-plant

and yard towing. ( For highway use, consult applicable
federal, state and local laws regarding requirements
for brakes, lights, fenders, etc. ).

Order:

• K958-1- Two Inch Ball Hitch

• K958-2- Lunette Eye Hitch

• K959-2- Fender and Light Kit

• K965-1- Cable Storage Rack

K889-2 Hand Moving Undercarriage

• K1631-1 Puncture proof Wheel Kit.

K889-3 Hand Moving Undercarriage - with
Puncture Proof Tires.

K893-1 Caster Kit for use with K889-2 & K889-3
K933-1 Four wheel undercarriage - for hand moving

• K934-1 Gas Cylinder Bracket

K1770-1 Factory undercarriage

• K1745-1 Gas Cylinder Bracket

K704 400 AMP Accessory Kit Which Includes:

• Electrode Holder & Cable

• Work Clamp & Cable

• Headshield

K894-1 Spark Arrester Kit - Includes a heavy gauge
steel, approved spark arrester and clamp for easy
mounting to muffler exhaust pipe.

K857 25ft. (7.5m) or K857-1 100 ft.(30.4m).
REMOTE OUTPUT CONTROL CABLE

K896-1 GFCI - 115V Receptacle Kit

TIG WELDING OPTIONS /
ACCESSORIES

K930-2 TIG Module - Provides high frequency and

shielding gas control for AC and DC CTAW (TIG)
welding applications. Its compact case is designed for
easy carrying, complete with a handle. High frequency
bypass is built in.
The TIG Module is supplied without accessories, Arc
Start switches, Amptrols, cables, torches and mount­ing brackets must be purchased separately.

K1737-1 Four Wheel all-terrain undercarriage, for
moving by hand with heavy duty puncture resistant
pneumatic tires.

K886-1 Canvas Cover

K1788 Roll Cage
K802-N Power Plug Kit - Provides four 115V plugs

rated at 20 amps each and one dual voltage, full KVA
plug rated at 115/230V, 50 amps. (For K1418-2 or
K1419-2 CSA machines and machines with GFCI
receptacles, use K802-R

K802-R Power Plug Kit - Provides four 115V plugs rated at
15 amps each and one dual voltage, full KVA plug rated at
115/230V, 50 amps.

K1690-1 GFCI RECEPTACLE KIT - Includes one UL

approved 120V ground fault circuit interrupter duplex
type receptacle with cover and installation instructions.
Replaces the factory installed 120V duplex receptacle.
Each receptacle of the GFCI Duplex is rated at 20 Amps,
the maximum total current from the GFCI Duplex is limit­ed to the 20 Amps. Two kits are required.

Optional:

• K939-1 Docking Kit Mounting Bracket

• K936-1 Control Cable - (9 to 14 )

• K963-1 Hand Amptrol

• K963-2 Hand Amptrol

• K870 Foot Amptrol

• K937-45 45 ft. Control Cable Extension

• K844-1 water valve kit

• K449 LN-25 with contactor, Solenoid

RANGER 9

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when
necessary and replace them when the mainte­nance requiring their removal is complete.
Always use the greatest care when working near
moving parts.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

--------------------------------------------------------

See additional warning information

throughout this operator’s manual

and the Engine manual as well.

ENGINE ADJUSTMENTS

ROUTINE MAINTENANCE

• At the end of each day’s use, refill the fuel tank to

minimize moisture condensation in the tank.
Running out of fuel tends to draw dirt into the fuel
system. Also, check the crankcase oil level and
add oil if indicated.

OIL - Maintenance schedule for changing the oil

•

and oil filter after break-in:

Kohler
CH20S

Oil

Oil Filter

The above schedule is for normal operating condi­tions. More frequent oil changes are required with
dusty, high temperature, and other severe operating
conditions. Refer to the maintenance section of the
Engine Owner’s Manual for more information.

100 HRS

200 HRS

Onan

P220OHV

100 HRS

200 HRS

CAUTION

Make certain that the oil filler cap is securely tight­ened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.

------------------------------------------------------------------------

Engine life will be reduced if the oil and oil filter
are not changed according to the manufacturer’s
recommendation.

ENGINE OIL CHANGE

Drain the oil while the engine is warm to assure rapid
and complete draining.

WARNING

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for this

machine is 3750RPM, no load. DO NOT tamper
with governor components or setting or make any
other adjustments to increase the maximum
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.

-----------------------------------------------------------------------­Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable contain­er.

• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.

RANGER 9

D-2

MAINTENANCE

D-2

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

• 1.5 US qt. (1.2 Imp qt., 1.4 liter)-Onan P220 OHV

With oil filter replacement:

• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

• 1.65 US qt. (1.4 Imp qt., 1.6 liter)-Onan P220 OHV

Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil con­tainer to be sure it includes the letters SG or SH.
SAE 10W-30 is recommended for general, all-temper­ature use, -5 F to 104 F (-20 C to 40 C). For the Onan
engine, it is recommended that SAE 30 oil be used
above 82 F (27 C).
See Engine Owner’s Manual for more specific infor­mation on oil viscosity recommendations.
Wash your hands with soap and water after handling
used oil.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you
take it in a sealed container to your local service sta­tion or recycling center for reclamation. Do not throw it
in the trash, pour it on the ground or down a drain.

OIL FILTER CHANGE

• Drain the engine oil.

• Remove the oil filter, and drain the oil into a suitable

container. Discard the used oil filter.

• Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.

• Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil fil­ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary. If brushes are
to be replaced, clean slip rings with a fine emery
paper.

CAUTION

Do not attempt to polish slip rings while engine is
running.

------------------------------------------------------------------------

Air Cleaner

•

With normal operating conditions, the maintenance
schedule for cleaning and re-oiling the foam pre-filter
is every 25 hours and replacement of the air cleaner
filter every 100 hours. More frequent servicing is
required with dusty operating conditions. Refer to the
maintenance section of the Engine Owner’s Manual
for more information.

• Refer to the maintenance section of the Engine
Owner’s Manual for the maintenance schedule for
spark plug servicing, cooling system servicing, and
and fuel filter replacement.

• Blowout the machine with low pressure air period­odically. In particularly dirty locations, this may be
required once a week.

• Output Ranger Selector and Polarity Switches:
Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the handle
from maximum to minimum setting twice each
morning before starting to weld.

• Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.

• Start the engine and check for oil filter leaks.

• Stop the engine, and check the oil level. If neces-

sary, add oil to the upper limit mark on

RANGER 9

D-3

MAINTENANCE

D-3

BATTERY CHARGING

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away
from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - discon­nect negative cable from old battery first
and connect to new battery last.

• CONNECTING A BATTERY CHARGER
Remove battery from welder by discon­necting negative cable first, then positive
cable and battery clamp. When reistalling,
connect negative cable last. Keep well

ventilated.

• USING A BOOSTER - connect positive lead
to battery first then connect negative lead
to engine foot.

• BATTERY ACID CAN BURN EYES and SKIN

Wear gloves and eye protection and be
careful when working near battery.

Follow instructions printed on battery.

------------------------------------------------------------------------

BATTERY

• When replacing, jumping, or otherwise connecting
the battery to the battery cables, the proper polarity
must be observed. Failure to observe the proper
polarity could result in damage to the charging
circuit.
The positive (+) battery cable has a red terminal

cover.

• If the battery requires charging from an external
charger, disconnect the negative battery cable first
and then the positive battery cable before attaching
the charger leads. Failure to do so can result in
damage to the internal charger components. When
reconnecting the cables, connect the positive cable
first and the negative cable last.

HARDWARE

Both English and Metric fasteners are used in this
welder.

Engine Maintenance Parts

ONAN P220OHV KOHLER CH20S

ONAN 122-0737 KOHLER 1205001

Oil Filter FRAM PH4967 FRAM PH3614*
Air Filter ONAN 187-6068 KOHLER 4708303

Element FRAM CA79
Air Filter N / A KOHLER 2408302

Pre-Cleaner
Fuel Filter ONAN187-6119 KOHLER 2505002

FRAM G1

Spark Plugs ONAN 167-1638 CHAMPION RC12YC
(Resistor NGK BPR4EY (.030” GAP)

Type) (.025” GAP)

* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.

RANGER 9

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 9

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS

E-2

RECOMMENDED

COURSE OF ACTION

No welder or output power.

Engine will not idle down to low
speed.

1. Open in miscellaneous leads.

2. Open lead in flashing or field
circuit.

3. Faulty rotor.

4. Faulty Potentiometer (R1).

5. Faulty stator Field winding.

6. Faulty Field rectifier (D2).

7. Faulty P.C. Board.

1. Idler switch on High Idle.

2. Insufficient voltage present
between terminals #213 and
#5E. (Voltage should be 12V
DC).

3. External load on welder or
auxiliary power.

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Engine will not go to high idle when
attempting to weld.

4. Faulty wiring in solenoid circuit.

5. Faulty idler solenoid.

6. Faulty P.C. Board.

1. Poor work lead connection to
work.

2. No voltage signal from the
current sensor.

3. No open circuit voltage on
output studs.

4. Faulty P.C. Board.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 9

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

RECOMMENDED

COURSE OF ACTION

E-3

Engine will not go to high idle when
using auxiliary power.

Engine will not crank or is hard to
crank.

Engine will not start or shuts down.

1. No voltage signal from the
current sensor.

2. Auxiliary power load less than
100 to 150 watts.

3. Faulty P.C. Board.

1. Battery will not hold a charge.
Faulty Battery.

2. No or insufficient charging
current.

3. Loose battery cable
connection(s).

4. Spark plugs fouled

1. Out of fuel.

2. Low oil level.

3. Fault in fuel system.

4. Oil pressure switch faulty.

5. Generator terminal block

connection faulty

6. Faulty P.C. Board (Onan engine)

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Engine does not develop full power.

Engine is hard to start.

1. Fuel filter clogged.

2. Air filter clogged.

1. Spark plugs do not have
specified gap.

2. Spark plugs are fouled.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

RANGER 9

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

RECOMMENDED

COURSE OF ACTION

E-4

Battery does not stay charged

Output control on welder not
functioning.

Output control or remote not
functioning.

1. Faulty battery.

2. Faulty charging system.

3. Loose or broken lead in charging
circuit.

1. Output control switch in wrong

position.

2. Output control switch defective.

3. Output control potentiometer

defective.

4. Faulty wiring.

5. Faulty P.C. Board.

1. Output control switch in wrong

position.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Wire feeder does not work when
connected to welder amphenol.

2. Remote control leads broken in

control cable.

3. Faulty wire feeder.

4. Faulty P.C. Board.

1. Wire feeder circuit open or

faulty.

2. No 115V or 24V output from

stator.

3. Faulty wiring in control cable.

4. Faulty wire feeder.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 9

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENTS(S)

E-5

RECOMMENDED

COURSE OF ACTION

Contactor does not pull in when
scratch starting when engine goes to
high idle.

Contactor does not pull in when
using a wire feeder with a control
cable plugged in to amphenol.

1. Welding terminal switch in wrong
position.

2. Faulty wiring in contactor circuit.

3. Faulty remote switch.

4. Faulty contactor.

5. Faulty P.C. Board PCB1.

1. “WELDING TERMINALS” switch

in wrong position.

2. Faulty wiring in contactor circuit.

3. Faulty amphenol or bypass P.C.

Board PCB2.

4. Faulty contactor.

5. Faulty P>C> Board PCB1.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Contactor does not drop out.

6. Faulty control cable from wire

feeder or amphenol.

7. Faulty wire feeder.

1. Faulty wiring.

2. Faulty amphenol or bypass

P.C. Board PCB2.

3. Faulty contactor.

4. Faulty P.C. Board PCB1.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

RANGER 9

F-1

WIRING DIAGRAM

F-1

208B

SHOWN IN

POSITION

"ALWAYS ON"

CONTROL SWITCH

WELDING TERMINAL

S6

POSITION

IN "RUN"

"S3" SHOWN

+-

R

(+)

209A

208C

214

232A

25W

RECTIFIER

208A

J1

224B

5A

DOES NOT APPEAR

A

5

1

219

201A

31,000 MFD

CAPACITORS

236A

236

D1

A

ON SOME OLDER

MACHINES

CB8

236A

(-)

ON

5D

247

AM 1

AMMETER

PC

PCB1

247

BOARD

2C

J3

4

12

6

13

2

3 TURNS

3

1 TURN

TOROID

254

L1

(CHOKE)

RANGER 9 WIRING DIAGRAM (CODES 10909 AND 10939)

250

J2

7

8

1

4

75

77

235

240

224E

76

242

236

232

224B

240

242

232

224E

CV-

WITH S2 IN

S2A (CLOSED

CV+

200B

C5

C4

C3

C2

POSITION)

C1, C2 OR C3

245

1

200

OUTPUT

235

242

AC

DC-

DC+

221

25A

201A

E

REACTOR

BUTTON

S7

START

211

R

5H

S5

"HIGH’

IDLER

POSITION

SHOWN IN

SWITCH

210

AUTO

5D

250

5C

L2

IDLER

SOLENOID

219

5A

214

232A

3

200B

75A

77

3

75

76D

R3

10K POT

CW

77D

OUTPUT

MAX

RHEOSTAT

76A

S2

C3

C2

C1

R6

R5

S2

R4

RANGE

SWITCH

R3

R2

R1

S1

240

241

25 OHM

50W

2

R

232

CR1

224E

224B

C3

W2

W1

232A

224

HIGH

77

76

S4

C2

BLOCK CONNECTION.

ENGINE TERMINAL

SEE DIAGRAM "A" FOR

224D

STATOR

C1

IN LINE CONNECTORS

210

224C

224A

76D

REMOTE POSITION)

REMOTE SWITCH

(SHOWN IN

7

9
6

GND-E
5

3

32

42

31

76A

(3 PLACES)

75A

2C

R

STARTER

CONTACTOR

SOLENOID

AND

U

SWITCH

OIL PRESSURE

W

1

4

3

2

A

211

208

221

5A

3

3

232A

2C

GROUND SCREW

BLOWER BAFFLE

224

77A

5E

GND-C

GND-G

GND-E

(10AMP)

CB1

5E

77A

31A

PCB2

BYPASS PC

224C

5B

5F

GND-D

8

4

MODULE

IGNITION

+

224A

5C

201A

201

N

E

E

R

125/250V. SINGLE

RECEPTACLE

N

E

3

K

C

A

L

B

J5

2A

75C

4A

4C

77C

76C

209A

-

5B

219

7

BLACK

G

E

R

5

1

SOL.

FUEL

SHUTOFF

(+)

VOLTAGE

V

FLYWHEEL

ALTERNATOR

ENGINE

HOUR METER

POSITIVE SLIP

SLIP

5H

RINGS

(-)

(-)

(+)

(+)

200B

200A

AC

(+)

D2

200

(+)

AC

9

5

5K

5L

J6

115 V

N

E

E

R

GND-D

G

CB2

6

G

COLORED

TERMINALS

SILVER

BLACK

11

K

C

J8

115/230V

GND-G

BLACK

50A

12

11

K

C

A

L

B

K

C

A

76A

J4

4

6

3

1

4B

2B

76B

77B

75B

12V

STARTER

REGULATOR

LAMINATION

RING NEAREST

ROTOR FIELD

C1

201

800 MFD

20A

CB4

115 V

GND-C

20A

CB5

A

L

B

5K

L

B

4

2

GND-H

(-)

ENGINE

MOTOR

5F

B-

ACAC B+

224C (CAVITY #4)

DIAGRAM "A"

ENGINE TERMINAL

BLOCK CONNECTION

211 (CAVITY #3)

(-)

K

C

A

L

B

3A

W

I

H

E

T

W

I

H

E

T

WHITE

5

5L

J7

SILVER

COLORED

TERMINALS

K

C

A

L

B

3B

TERM.

COLORED

SILVER

W

I

H

E

T

50A

CB3

B

K

C

A

L

3B

K

C

A

L

B

3A

3

77A

J3

3

5E

1

2C

77A

75A

76A

4C

GND

S1

SWITCH

ELECTRODE POLARITY

OUTPUT

CONTACTOR

ELECTRODE

WORK

42

31B

21

75C

2A

4A

76C

77C

32

31A

21

AMPHENOL 1

J

A

115VAC

D

CONTACTOR

C

H

WORK

REMOTE CONTROL

GND-A

K

B

F

I

G

E

42VAC

77B

ABC

GROUND

REMOTE CONTROL

2B

4B

76B

75B

GND-B

F

D

E

CONTACTOR

AMPHENOL 2

GROUND

CROSS

ENGINE

SUPPORT

FOOT

WELDER LEAD END

TAB

LOCATING

AMPHENOL HOLES

GROUND SCREW BETWEEN

A

G4228

(NOTE CAVITY NUMBERS)

208 (CAVITY #2)

221 (CAVITY #1)

RANGER 9

NOTES:

LEADS LABELED BLACK MAY BE GRAY.

ALL CASE FRONT COMPONENTS VIEWED FROM REAR.

ELECTRICAL SYMBOLS PER E1537

6

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

F-2

DIAGRAMS

F-2

RANGER 9

OPTIONAL K444-1
REMOTE CONTROL

TO WORK ELECTRODE

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE
OUTPUT SELECTOR SWITCH TO CV POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTORL IS USED, PLACE OUTPUT CONTROL SWITCH
IN "OUTPUT CONTROL REMOTE" POSITION.
N.D. WELDING TERMINALS SWITCH MUST BE PLACED IN "ALWAYS ON" POSITION.

12-18-93

M17090

RANGER 9 / K867 / K775 / LN-7 CONNECTION DIAGRAM

WARNING

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.

Do not touch electrically live parts.

SPARE

82

81

42

41

31

32

14 PIN
AMPHENOL

TO WORK

ELECTRODE

TO WORK

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE
TO WIRE FEED UNIT

2

4

21

GND

75

76

77

CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.
N.F. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

Keep guards in place.
Keep away from moving parts.

Only qualified personnel should install,use
or service this equipment.

N.D.

31

32

2

4

21

GND

GREEN

75

76

77

N.E.

LN-7
WIRE
FEEDER

K291 OR K404
INPUT CABLE

K775 OPTIONAL
REMOTE CONTROL

12-16-93

M17091

RANGER 9

F-3

DIAGRAMS

F-3

RANGER 9

TO WORK ELCTRODE

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELCTRODE POLARITY, POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.
PLACE WELDING TERMINAL SWITCH TO "REMOTELY CONTROLLED" POSITION.
N.B. WELDING CABLE MUST BE OF PROPER CAPCITY FOR THE CURREENT AND DUTY CYCLE OF IMMEDIATE AND FUTRE
APPLICATIONS. SEE OPERATING NMANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION.

IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

-XX INPUT

IDLE

12-16-93

M17092

RANGER 9 TO K867 ADAPTER CONNECTION DIAGRAM

WARNING

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.

Do not touch electrically live parts.

K867 UNIVERSAL

ADAPTER PLUG

ELECTRODE CABLE
TO WIRE FEED UNIT

TO WORK

81
82

SPARE

2

4
41
42

31
32

GND

21

77
76
75

14 PIN

AMPHENOL

TO WORK

ELECTRODE

CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.B. USE POLARITY SWITCH TO SET DESIRED POLARITY, POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT, USE ISOLATION

RELAY TO CLOSE LEADS 2 & 4.

N.E. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW.

Keep guards in place.
Keep away from moving parts.

Only qualified personnel should install,use
or service this equipment.

N.C.

NOT USED ON RANGER POWER SOURCES

CONNECT TOGETHER FOR

WELDING OUTPUT

42 VAC

115 VAC

POWER SOURCE FRAME CONNECTION

WIRE FEEDER VOLTMETER CONNECTION
CONNECTS TO (WORK TERMINAL) OF POWER SOURCE

10K

REMOTE OUTPUT CONTROL

MIN.

TO

K867

N.E.

2

4

N.D.

TO

WIRE
FEEDER

RANGER 9

12-16-93

M17093

F-4

DIAGRAMS

RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM

RANGER 9 / K867 / LN-8 CONNECTION DIAGRAM

WARNING

WARNING

Do not operate with panels open.

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD

Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.

before servicing.

Do not touch electrically live parts.

Do not touch electrically live parts.

SPARE

SPARE

82

82

81

81

42

42

41

41

31

31

32

32

2

21

21

GND

GND

75

75

76

76

77

77

2

4

4

14 PIN

14 PIN

AMPHENOL

AMPHENOL

ELECTRODE

TO WORK

TO WORK

CAUTION :

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.

N.D. SPLICE LEADS AND INSULATE.
N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

N.E. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

ELECTRODE

ELECTRODE CABLE

ELECTRODE CABLE
TO WIRE FEED UNIT

TO WORK

TO WORK

PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION. PLACE WELDING TERMINALS SWITCH TO

PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITION. PLACE WELDING TERMINALS SWITCH TO
"REMOTELY CONTROLLED " POSITION.

"REMOTELY CONTROLLED " POSITION.

TO WIRE FEED UNIT

K867 UNIVERSAL

K867 UNIVERSAL
ADAPTER PLUG

ADAPTER PLUG

Keep guards in place.

Keep guards in place.
Keep away from moving parts.

Keep away from moving parts.

Only qualified personnel should install,use

Only qualified personnel should install,use
or service this equipment.

or service this equipment.

N.C.

N.C.

31

31

32

32

2

2

4

4

21

21

GND

GND

A

A

B

B

C

C

N.D.

N.D.

K196

K196
INPUT CABLE

INPUT CABLE

LN-8

LN-8
WIRE

WIRE
FEEDER

FEEDER

M17094

M17094

12-16-93

12-16-93

F-4

RANGER 9 / LN-742 CONNECTION DIAGRAM

WARNING

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.

Do not touch electrically live parts.

TO LN-742 INPUT

14 PIN

CABLE PLUG

AMPHENOL

K592 CONTROL CABLE

TO WORK

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.

ELECTRODE

TO WORK

Keep guards in place.
Keep away from moving parts.

Only qualified personnel should install,use
or service this equipment.

ELECTRODE CABLE

TO WIRE FEED UNIT

RANGER 9

12-16-93

M17100

F-5

DIAGRAMS

RANGER 9 / LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM

WARNING

F-5

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.

Do not touch electrically live parts.

Keep guards in place.
Keep away from moving parts.

Only qualified personnel should install,use
or service this equipment.

TO LN-25 INPUT

14 PIN

CABLE PLUG

AMPHENOL

K626-XX INPUT CABLE ASSEMBLY

TO WORK

ELECTRODE

ELECTRODE CABLE

TO WIRE FEED UNIT

CAUTION :

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

N.B. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED, PLACE OUTPUT CONTROL SWITCH IN "OUTPUT CONTROL REMOTE" POSITIION.
N.D. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED.

TO WORK

K915-1 AMPTROL ADAPTER FOR K799 HI-FREQ KIT

12-16-93

M17214

WARNING

ELECTRIC SHOCK

can kill

K963 HAND

AMPTROL

OR

K870 FOOT

AMPTROL

THIS ADAPTER ALLOWS AN AMPTROL TO OPERATE A K799
HI-FREQ KIT WHILE REMOTELY CONTROLLING THE
OUTPUT CURRENT OF A LINCOLN P OWER SOURCE.
(THE POWER SOURCE MUST BE EQUIPPED WITH A
6-PIN REMOTE CONTROL AMPHENOL CONNECTOR.)
SEE THE HI-FREQ KIT AND P OWER SOURCE INSTRUC­TION MANUAL FOR INFORMATION ON PROPER SWITCH
AND CONTROL SETTINGS.

TURN THE ENGINE OR PO WER SWITCH

OF THE WELDING POWER SOURCE "OFF"

BEFORE CONNECTING OR DISCONNECTING

PLUGS TO WEL DING POWER SOURCE.

K915-1
AMPTROL
ADAPTER

6-SOCKET

RECEPTACLE

6-PIN
PLUG

5-PIN
PLUG

POWER SOURCE

-

CAPACITOR

HI-FREQ KIT
INPUT POWER

SEE INSTRUCTIONS INCL UDED WITH HI-FREQ

*

KIT FOR CONNECTION INFORMATI ON.

+

BYPASS

*

KIT

*

K799 HI-FREQ KIT

ELECTRODE LEAD
WORK SENSE LEAD

4-19-96D

S20909

*

*

RANGER 9

F-6

DIAGRAMS

RANGER 9 AND 10LX / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM

WARNING

F-6

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing.

Do not touch electrically live parts.

115V RECEPTACLE

RANGER

14 PIN WIRE FEEDER
RECEPTACLE

TO WORK

ELECTRODE

TO WORK

CAUTION :

N.A. WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION.
N.B. USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO A CV POSITION.

N.C. IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE,PLACE OUTPUT CONTROL SWITCH IN
"OUTPUT CONTROL REMOTE" POSITION.

N.D. PLACE IDLER SWITCH IN "HIGH" IDLE POSITION.

BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE "LINCOLN" (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE

CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

PLACE WELDING TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION.

6 PIN REMOTE
RECEPTACLE

ELECTRODE CABLE
TO CONTROL MODULE

Keep guards in place.
Keep away from moving parts.

Only qualified personnel should install,use
or service this equipment.

K488 SG
CONTROL MODULE

K691-10
INPUT CABLE

K487-25
SPOOL GUN

4-7-95B

M17902

RANGER 9

F-7

DIMENSION PRINT

CENTER OF GRAVITY WITH OIL IN

ENGINE AND EMPTY FUEL TANK.

.25

+

-

20.63

20.51

30.00

30.00

8.80

F-7

42.00

42.25

UNDERCARRIAGE MOUNTING HOLES

DIMENSION PRINT- RANGER 9

OF SHAFT

L

C

9.299.31

30.28

26.59

.25

+

-

12.75

9.09

9.09

RANGER 9

FOR OIL FILTER

REMOVAL (NOT

REQUIRED WITH

2.75

KOHLER ENGINE)

17.00

NOTES

RANGER 9

NOTES

RANGER 9

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

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AVISO DE

PRECAUCION

French

ATTENTION

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WARNUNG

Portuguese

ATENÇÃO

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LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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